Collapsible container for air shipment cargo and method of use

ABSTRACT

A collapsible container for air shipment cargo comprises a base, a top, front and rear wall panels hingedly secured to the base and side walls hingedly secured to the base and top. Each of the side walls has upper and lower wall panels hinged together so as to enable each side wall to collapse inwardly. A hinged door is formed in one of the side walls. Flaps having fasteners are hingedly secured to the side walls and used to assemble the container. Portions of the top have fasteners which are used to secure the front and rear wall panels to the top. The rear panel has upper and lower portions forming an obtuse angle with each other when the container is assembled.

FIELD OF THE INVENTION

The present invention relates to a collapsible container for use in an aircraft cargo hold.

DESCRIPTION OF THE PRIOR ART

Special containers are used on aircrafts for storing fragile parcels containing breakable or perishable goods, or for storing passenger luggage. Due to the limited space available in aircraft cargo holds, the shape of such a container is generally designed to fit the shape of the walls of the aircraft cargo hold or luggage compartment. One of the most important factors airlines use in selecting a suitable container for use in an aircraft cargo hold is gross weight. The heavier the container, the heavier the airplane and the more fuel must be used to fly a predetermined distance.

In order to reduce the space occupied by such a container once it has been emptied, such a container has been designed to collapse. For example, U.S. Pat. No. 5,890,612 discloses a collapsible aircraft container which has a rigid base frame supporting an accordion folding frame. The collapsible container has sides made of canvas and sheet metal plates. The frames are made of steel. Therefore, the container is heavy, even when empty.

Another collapsible aircraft container is disclosed in U.S. Pat. No. 5,941,405. This collapsible aircraft container has a base, support posts and roof made of aluminum and flexible side walls formed from light weight fabric. Again, due to the support posts, the container is heavy, even when empty.

In each of these collapsible aircraft containers, the less the weight the better, as long as the container is sturdy enough to handle normal wear and tear of such use. Consequently, there is a need for a light weight, collapsible airline container which does not include a frame or support posts, thereby reducing its weight.

SUMMARY OF THE INVENTION

The collapsible container of the present invention comprises a base, a top, front and rear wall panels hingedly secured to the base and side walls hingedly secured to the base and top. Each of the side walls comprises upper and lower wall panels hinged together so as to enable each side wall to collapse inwardly. A hinged door is formed in one of the side walls for access to the interior of the erected container.

Once the container is erected, a person may load product(s) or luggage into the interior of the container for shipping purposes. Likewise, prior to collapsing the container, product(s) or luggage may be removed from the interior of the container out the opening or openings formed in one or both of the side walls of the container which may be closed doors or other similar structure.

Although the collapsible container of the present invention is intended for use inside airplane cargo holds or luggage compartments, it may used in any desired environment and is not intended to be limited in its use.

In one embodiment of the present invention, the top of the collapsible airline container is one piece or panel of material having two opposed flanges which may be bent downwardly perpendicular to the generally planar main portion of the top. Fasteners are secured to these flanges in any suitable manner and in one embodiment comprise rotatable latches adapted to pass through openings in the front and rear wall panels of the container during assembly of the container. Of course, any other suitable fasteners may be used to secure the top to the collapsible front and rear wall panels of the assembly during assembly.

The front wall panel of the container in one embodiment comprises one generally rectangular piece or panel of plastic material. However, the front wall panel or front wall may be made of multiple pieces secured together of any suitable material.

The rear wall panel in one embodiment comprises one generally rectangular piece or panel of plastic material. The rear wall panel has a living hinge extending from one side edge to the other side edge which separates the rear wall panel into a generally planar upper portion or section and a generally planar lower portion or section and enables the rear wall panel to be folded into a collapsed position when the container is collapsed. These upper and lower portions or sections of the rear wall panel form an obtuse angle with each other when the container is assembled and lay on top of one another when the container is collapsed. If desired, the rear wall may be made of multiple pieces secured together of any suitable material.

The collapsible airline container further comprises plastic flaps hingedly secured to the side walls. These flaps are secured to the front and rear wall panels of the container during assembly of the container. In one embodiment, three flaps are hingedly secured to one edge of each side wall for securing the side wall to the rear wall panel and two flaps are hingedly secured to an opposing edge of the side wall for securing the side wall to the front wall panel. At least one fastener is secured to each of the flaps. In one embodiment these fasteners comprise rotatable latches adapted to pass through openings in the front and rear wall panels. Of course, any other suitable fasteners may be used to secure the flaps to the collapsible front and rear wall panels.

Each of the wall panels and flaps is preferably made of plastic but may be made of any suitable material. In one embodiment of the present invention, each of the wall panel is made of a plastic material sold under the mark CON-PEARL® by Friedola Gebr. Holzapfel Gmbh & Co. of Germany. The panel material may be selected as appropriate to protect or prevent surface damage to the products being stored and/or shipped in the erected container.

The method of assembling the collapsible airline container comprises multiple steps. Although the method is described with respect to one preferred embodiment, the method may be used with any of the embodiments contemplated by this invention.

In one instance, a collapsed container as described above is first provided. Two operators first lift a top of the collapsed container, thereby erecting side walls of the collapsed container including a collapsed door. The operators then lift, pivot or raise the front and rear wall panels of the collapsed container by pulling on straps secured to these panels of the collapsed container.

One of the assemblers then enters the interior of the container via the open door of the partially erected container. The first assembler located outside the partially erected container passes rotatable latches located on the flanges of the top of the container through openings in the front and rear wall panels of the container. The assembler located inside the container then rotates the latches to prevent the latches from passing back through the openings in the front and rear wall panels of the container. The second assembler located outside the container also passes the fasteners in the form of rotatable latches located on the flaps of the container through openings in the front and rear wall panels of the container. The assembler located inside the container then rotates the latches to prevent the latches from passing back through the openings in the front and rear wall panels of the container and secure the flaps to the front and rear wall panels of the container.

After the interior of the erected container is loaded with product, one of the assemblers may close and lock the door of the container in a closed position.

In this manner, the container may be quickly and inexpensively assembled or erected. For purposes of this document, the term “fastener” refers to any type of fastener including a rotatable latch.

In order to disassemble the container, a person enters the interior of the erected container and rotates the rotatable latches to open them so that the flaps may be separated from the front and rear wall panels and the top may be separated from front and rear wall panels by a second operator located outside the container. After the person previously inside the interior of the container exits the container via the opening where the door is located, the other person pulls the flaps away from the front and rear wall panels and collapses the front and rear wall panels after the top has been separated from the front and rear wall panels. After the rear wall panel has been collapsed, the front wall panel is collapsed then the side walls are collapsed. The container is now fully collapsed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the container of the present invention in an erected condition;

FIG. 2 is a perspective view of the container of the present invention in an collapsed condition;

FIG. 3 is a perspective view of the collapsed container of FIG. 2 illustrating the side walls being erected;

FIG. 4 is a perspective view of the container of FIG. 3 illustrating the side walls fully erected;

FIG. 5 is a perspective view of the container of FIG. 4 illustrating the front and rear wall panels being erected;

FIG. 6 is a perspective view of the container of FIG. 5 illustrating the flaps being secured to the front wall panel of the erected container;

FIG. 7A is a perspective view of one of the rotatable latches used in accordance with the present invention in an unlocked position;

FIG. 7B is a perspective view of the rotatable latch of FIG. 7A in a locked position;

FIG. 8 is a perspective view of the erected container of FIG. 1 illustrating the base of the container;

FIG. 9 is a rear elevational view taken along the line 9-9 of FIG. 2;

FIG. 10 is a perspective view of the erected container of FIG. 1 illustrating products being placed into the interior of the container; and

FIG. 11 is a view taken along the line 11-11 of FIG. 8.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings and particularly to FIG. 1, there is illustrated a collapsible container 10 movable between an erected condition or position illustrated in FIGS. 1 and 8 and a collapsed condition or position illustrated in FIGS. 2 and 9. The collapsible container 10 is designed for use inside an aircraft luggage hold but may be used in other environment or for any other purpose.

As best illustrated in FIG. 8, the collapsible container 10 comprises a generally rectangular and generally planar base 12 having an upwardly directed flange 13 around the periphery thereof. The base 12 is preferably made of one piece of plastic material. However, other materials or other configurations may be used without departing from the present invention.

Although reference is made to made in this document to a front wall panel, a rear wall panel and side walls, it will be appreciated that the collapsible container 10 may be oriented in any direction so that, for example, the front wall panel is actually at the rear of the erected container.

As shown in FIG. 1, a pair of side walls 14 are hingedly secured to the base 12 and more particularly to upwardly directed flanges 13 located around the periphery of the base 12 with horizontally oriented hinges 16 shown in FIG. 9. Each hinge 16 is preferably a co-extruded plastic hinge made by the Bradford Company of Holland, Mich. but may be any other type of hinge.

Each side wall 14 comprises a lower wall panel 18 hingedly secured to an upper wall panel 20 with a horizontally oriented hinge 22. Each hinge 22 is preferably a co-extruded plastic hinge like hinges 16, but may be any other type of hinge. Each wall panel 18, 20 is preferably made of one piece of plastic material, but may be multiple pieces or made with any other suitable material. Although the wall panels 18, 20 of each side wall 14 are preferably made of the same material, they may be different materials.

As shown in FIGS. 3 and 9, hinges 22 enable each side wall 14 to fold or collapse inwardly so that the upper wall panel 20 overlays or lays on top of the lower wall panel 18 when the container 10 is collapsed. As shown in FIG. 9, each hinge 22, as well as each hinge 16, comprises a pair of U-shaped receptacles 23 and a flexible joining member 25 joining the receptacles 23 and enabling them to move relative to one another.

As shown in the figures, at least one of the side walls 14 has a collapsible door 24 adapted to cover an opening 26 formed in the side wall. See FIG. 10. The door 24 is hingedly joined to the side wall 14 with a vertically oriented hinge 28 and movable between a closed position as shown in FIG. 1 and an open position as shown in FIG. 10. The door 24 has an upper portion or section 30 and a lower portion or section 32 separated by hinge 22. In the illustrated embodiment, each section 30, 32 comprises one piece of plastic; however, other materials of any desired size may be used for the door sections.

Each section 30, 32 of door 24 may be latched or locked in a closed position with a latch 34 a, 34 b, respectively. As seen in FIG. 6, a portion of each latch 34 a, 34 b is located on the door section 30, 32 and another portion of the latch 34 a, 34 b is located on one of the side wall panels 20, 18. See FIG. 10. In one embodiment, each latch 34 a, 34 b is manufactured by McMaster-Carr of Aurora, Ohio. Latch 34 a is sold as part number 10425 A86 and latch 34 b is sold as part number 10425 A84. See www.mcmaster.com. Either of the latches may be locked if desired. However, latches 34 a, 34 b may be any other suitable latching or locking members.

FIG. 11 illustrates hinge 28 in further detail. In one embodiment, hinge 28 is a 270 degree hinge extrusion manufactured by Filtrona Extrusion of Athol, Mass. and sold as part number 1440. See www.filtrona.com. However, hinge 28 may be any other suitable hinge. Hinge 28 comprises a pair of generally U-shaped receptacles 29, retaining lower wall panel 18 and the lower section 32 of the door 24, respectively in any desired manner. The hinge 28 further comprises a joining member 31 which enables movement of the receptacles 29 and their contents relative to one another.

As best seen in FIG. 3, flaps 36 a, 36 b and 36 c are hingedly secured to side edges 38 a, 38 b and 38 c, respectively, of each side wall 14. More particularly, upper flaps 36 a are hingedly secured to side edges 38 a of upper wall panels 20 with hinges 40 a. Similarly, middle flaps 36 b are hingedly secured to side edges 38 b of lower wall panels 18 with hinges 40 b. Lastly, lower flaps 36 c are hingedly secured to side edges 38 c of lower wall panels 18 with hinges 40 c.

As seen in FIGS. 3 and 4, on the other end of each side wall 14, flaps 36 d and 36 e are hingedly secured to side edges 38 d and 38 e, respectively, of each side wall 14. More particularly, flaps 36 d are hingedly secured to side edges 38 d of upper wall panels 20 with hinges 40 d. Similarly, flaps 36 b are hingedly secured to side edges 38 e of lower wall panels 18 with hinges 40 e.

Preferably, each flap 36 a-36 e is a single piece of plastic material. However, any of the flaps may be made of any number of pieces of any suitable material and of any desired size.

In one embodiment, hinges 40 a-40 e, all used to secure flaps to side wall panels 18, 20, are 270 degree hinge extrusions like hinge 28 used on the door 24, shown in detail in FIG. 11 and manufactured by Filtrona Extrusion of Athol, Mass. and sold as part number 1440. See www.filtrona.com. However, these hinge may be any other suitable hinges.

As shown in FIG. 6, the collapsible container 10 further comprises a front wall panel 42 hingedly joined to base 12 with horizontally oriented hinge 44. Hinge 44 in the embodiment shown is the same hinge as hinges 16 and 22 shown in detail in FIG. 9 and described above. As best shown in FIGS. 3 and 4, front wall panel 42 has at least one hole or opening 46 therethrough at the end of the front wall panel 42 opposite where it is joined to base 12 with hinge 44. This end becomes the top of the front wall panel 42 when the container 10 is erected. Similar holes or openings 48 through the front wall panel 42 are located along the sides of the front wall panel 42. As shown in FIG. 6, a nylon strap 50 is secured at its upper end 52 to the outside surface 54 of the front wall panel 42 and used for raising the front wall panel 42 from a horizontal collapsed position shown in FIGS. 3 and 4 to an erected or raised position shown in FIG. 6.

As best shown in FIGS. 1 and 8, the collapsible container 10 further comprises a rear wall panel 56 hingedly joined to base 12 with horizontally oriented hinge 58. Hinge 58 in the embodiment shown is the same hinge as hinges 16 and 22 shown in detail in FIG. 9 and described above. (also the same as hinge 44 shown in FIG. 6). As best shown in FIG. 5, rear wall panel 56 has a living hinge, crease or fold 60 separating the rear wall panel 56 into an upper portion or section 62 and a lower portion or section 64. As best illustrated in FIG. 8, when the container 10 is erected, the upper portion 62 is vertically oriented and forms an obtuse angle 66 with the lower portion 64. As best illustrated in FIG. 5, when the container 10 is collapsed, the upper portion 62 lays on top of the lower portion 64.

Like the front wall panel 42, the rear wall panel 56 has at least one hole or opening 68 therethrough at the end of the rear wall panel 56 opposite where it is joined to hinge 58. This end becomes the top of the rear wall panel 56 when the container 10 is erected. Similar holes or openings 70 through the rear wall panel 56 are located along the sides of the rear wall panel 56 to aid in erecting the container 10. See FIG. 5. As shown in FIG. 5, a nylon strap 72 is secured at one end 74 to the outside surface 76 of the rear wall panel 56 and used for raising the rear wall panel 56 from a horizontal collapsed position shown in FIGS. 3 and 4 to an erected or raised position shown in FIGS. 1 and 8. As shown in FIG. 5, when the rear wall panel 56 is collapsed, an inner surface 78 of the upper portion 62 of the rear wall panel 56 is upwardly directed while an inner surface 78 a of the lower portion 64 of the rear wall panel 56 is downwardly directed.

It is within the contemplation of the present invention that other devices other than nylon straps 50, 72 may be used to raise the front and rear wall panels 42, 56, respectively.

The collapsible container 10 further comprises a top or top panel 80 hingedly joined to the upper wall panels 20 of the side walls 14 with horizontally oriented hinges 82. Hinge 82 in the embodiment shown is the same hinge as hinges 16 and 22 shown in detail in FIG. 9, hinge 44 shown in FIG. 6 and hinge 58 shown in FIG. 8, described above. Any other suitable hinge may be used if desired. As best shown in FIGS. 3 and 4, top 80 has a pair of flanges 84 extending downwardly from a main portion 85 of the top 80.

As shown in FIG. 7A, at least one fastener in the form of a rotatable latch 86 is secured to each flange 84 of the top 80. The rotatable latch 86 may be riveted or secured in any suitable manner to an inside surface 88 of flange 84. The rotatable latch 86 comprises a stationary portion 90 and a rotatable portion 92. See FIGS. 7A and 7B. One fastener or rotatable latch which has proven satisfactory is manufactured by Friedola Tech Holzapfel Gmbh of Germany and sold as part number M931020. See http://www.friedola-tech.de. However, any other suitable latch or fastener may be used.

Referring to FIG. 5, in order to secure the rear wall panel 56 to the flange 84 of the top 80, the rotatable portion 92 of the latch 86 is passed through opening 68 in the rear wall panel 56 in its position shown in FIG. 7A and then rotated to a locked position shown in FIG. 7B.

As shown in FIG. 5, at least one fastener in the form of a rotatable latch 86 is secured to an inside surface of each flap 36 a-36 e and adapted to pass through holes 70 in the rear wall panel 56. Similarly, at least one fastener in the form of a rotatable latch 86 is secured to an inside surface of each flap 36 d and 36 e and adapted to pass through holes 48 in the front wall panel 42.

Referring to FIG. 3, the method of assembling the collapsible container 10 will now be described. Beginning with the collapsed container 10 shown in FIG. 2, two operators or assemblers 94 a and 94 b are provided. Simultaneously, they lift the top 80 or upper portions 20 of the side walls 14 up as shown in FIG. 3, thereby erecting the side walls 14 of the container 10 including the door 24. At this point, the front and rear wall panels 42, 56 of the container 10 are still in their collapsed condition or position. See FIGS. 3 and 4. FIG. 4 shows the container with the side walls 14 fully erect and the flaps 36 a-36 e located outside the side walls 14 of the container.

As shown in FIG. 5, assemblers 94 a and 94 b grab straps 72, 50, respectively and pull them upwardly to raise or pivot upwardly rear wall panel 56 and front wall panel 42, respectively. Front wall panel 42 is raised first by operator 94 b since it lays on top of rear wall panel 56 when the front and rear wall panels 42, 56 are collapsed above base 12.

As shown in FIG. 6, after the front and rear wall panels 42, 56 are erected or raised, one of the assemblers 94 a opens the door 24 and enters the interior of the partially erected container 10. The other assembler 94 b stays outside the container 10. The assembler 94 a passes the rotatable portions 92 of rotatable latches 96 secured to flanges 84 of top 80 through openings 46, 68 in the front and rear wall panels 42, 56, respectively. See FIG. 7A. The assembler 94 a inside the container 10 then rotates the rotatable portions of latches 96 as shown in FIG. 7B to secure the top 80 of the container to the front and rear wall panels 42, 56 of the container. Additionally, the assembler 94 a passes the rotatable portions 92 of rotatable latches 96 secured to flaps 36 a-36 e through openings 48,70 in the front and rear wall panels 42, 56, respectively. See FIG. 7A. The assembler 94 a inside the container 10 then rotates the rotatable portions of latches 96 as shown in FIG. 7B to secure the flaps 36 a-36 e of the container 10 to the front and rear wall panels 42, 56 of the container 10, the flaps 36 a-36 e being outside the front and rear wall panels 42, 56 of the container 10.

After the container 10 is fully assembled, the door may be closed and locked, if necessary, after products or items 96 are loaded inside the interior 98 of the container 10. See FIG. 10.

Although the figures illustrate a known method of assembling one embodiment of collapsible container, any other suitable known method may be used to assembly a collapsed container.

While I have described only one embodiment of my invention in detail, I do not intend to be limited except by the scope of the following claims. 

1. A collapsible container comprising: a base; a front wall panel hingedly secured to said base; a rear wall panel hingedly secured to said base; side walls hingedly secured to said base and a top, each of said side walls being collapsible inwardly; a door hinged to one of said side walls; said top having two opposed flanges adapted to be secured to said front and rear wall panels with fasteners for erecting the container; flaps hingedly secured to said side walls, wherein said flaps are secured to said front and rear wall panels with fasteners.
 2. The collapsible container of claim 1 wherein said front and rear wall panels each have a strap secured thereto to aid in assembly of said container.
 3. The collapsible container of claim 1 wherein said wall panels are plastic.
 4. The collapsible container of claim 1 wherein said fasteners are rotatable latches.
 5. The collapsible container of claim 1 wherein each of said side walls has an upper wall panel hinged to a lower wall panel.
 6. The collapsible container of claim 5 wherein said door has an upper portion hinged to a lower portion.
 7. The collapsible container of claim 5 wherein said door is lockable in a closed position.
 8. A collapsible container comprising: a base; a top having two opposed flanges; a front wall panel hingedly secured to said base; a rear wall panel having a upper portion and a lower portion, said lower portion being hingedly secured to said base and forming an obtuse angle with said upper portion of said rear wall panel when said container is assembled; side walls hingedly secured to said base and said top, each of said side walls having upper and lower wall panels hinged together so as to enable said side wall to hinge and collapse inwardly; flaps hingedly secured to said side walls; wherein said flanges of said top are secured to said front and rear wall panels with fasteners and said flaps are secured to said front and rear wall panels with fasteners when said container is erected.
 9. The collapsible container of claim 8 wherein each of said flaps have rotatable fasteners attached thereto which pass through openings in said front and rear wall panels before being rotated to assemble said container.
 10. The collapsible container of claim 8 wherein said wall panels are made of plastic.
 11. The collapsible container of claim 8 wherein said fasteners are rotatable latches.
 12. The collapsible container of claim 8 further comprising a door having an upper portion hinged to a lower portion.
 13. A collapsible container comprising: a base; a top; a front wall panel hingedly secured to said base and secured to said top with rotatable latches; a rear wall panel hingedly secured to said base and secured to said top with rotatable latches; side walls hingedly secured to said base and top, each of said side walls having upper and lower wall panels hinged together and being collapsible inwardly; flaps hingedly secured to said side walls, wherein said flaps are secured to said front and rear wall panels with rotatable latches; and a door hinged to one of said side walls.
 14. The collapsible container of claim 13 wherein each of said flaps has rotatable latches thereon which pass through said front and rear wall panels and are rotated when said container is assembled.
 15. The collapsible container of claim 13 wherein said top has opposed flanges, each of said flanges having rotatable latches thereon which pass through said front and rear wall panels and are rotated when said container is assembled.
 16. The collapsible container of claim 13 further comprising hinges joining said side wall panels to said base.
 17. The collapsible container of claim 13 wherein said door has an upper portion hinged to a lower portion.
 18. The collapsible container of claim 13 wherein said door may be locked in a closed position.
 19. A method of assembling a collapsible container, the method comprising the steps of: providing a collapsed container; lifting a top of the collapsed container, thereby erecting side walls of the collapsed container including a collapsed door; lifting front and rear wall panels hingedly secured to a base of the collapsed container; passing rotatable latches located on the top of the container through openings in the front and rear wall panels of the container; rotating the latches to prevent the latches from passing through the openings in the front and rear wall panels of the container; passing rotatable latches located on flaps of the container through openings in the front and rear wall panels of the container, said flaps being hingedly secured to said side walls of the container.
 20. The method of claim 19 further comprising closing the door of the container.
 21. The method of claim 19 wherein lifting said front and rear wall panels of the collapsed container comprises pulling on a strap secured to each of said front and rear wall panels.
 22. A method of assembling a collapsible container, the method comprising the steps of: providing a collapsed container having a top with opposed flanges, each of said flanges having rotatable latches thereon; raising the top of the collapsed container, thereby erecting collapsed side walls of the collapsed container, each of the side walls having flaps hingedly secured thereto and at least one of the side walls having a collapsible door formed therein; lifting front and rear wall panels hingedly secured to a base of the collapsed container; passing said rotatable latches located on the flanges of the top of the container through openings in the front and rear wall panels of the container; rotating the latches to secure the top of the container to the front and rear wall panels of the container; passing rotatable latches located on the flaps of the container through openings in the front and rear wall panels of the container; rotating the latches on the flaps to secure the flaps of the container to the front and rear wall panels of the container. 